Methods of joining and repairing composite components

ABSTRACT

A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

This application is a continuation of U.S. patent application Ser. No.16/378,086 filed Apr. 8, 2019, now U.S. Pat. No. 11,084,228, which ishereby incorporated herein by reference in its entirety.

BACKGROUND 1. Technical Field

This disclosure relates generally to methods for joining and repairingcomponents, and more particularly to methods for joining and repairingthermoplastic composite components.

2. Background Information

Components made from thermoplastic composite materials are increasinglyin demand in the aircraft and other industries as a result of thewide-ranging advantages of the materials. Thermoplastic compositematerials can be used to form lightweight and high-strength structureshaving complex shapes. In addition, thermoplastic composites, ascompared to thermosets, offer practically infinite shelf life, fastercycle time, the ability to be recycled/reformed, improved damagetolerance properties, as well as moisture and chemical resistance.

However, widespread adoption of thermoplastic composites in someindustries, such as the aircraft industry, has been limited as a resultof challenges with thermoplastic components manufacturing and repair.Current methods of joining thermoplastic components may use adhesives orthermoplastic films to join two or more components, thereby formingjoints between the two or more components which may exhibit reducedstructural strength. Accordingly, improved methods for manufacturing andrepairing thermoplastic components which meet industry, safety,airworthiness, and fast throughput requirements are desirable to supportindustry's increased production rates.

SUMMARY

According to an embodiment of the present disclosure, a method forjoining thermoplastic components is provided. A first thermoplasticcomponent and a second thermoplastic component including a first jointportion and a second joint portion, respectively, are provided. A leasta portion of a surface area of each of the first and second jointportions include a respective first and second mating surface. The firstand second mating surfaces of the respective first and second jointportions are positioned in contact with one another. The first andsecond joint portions are fusion-joined resulting in a single component.Fusion-joining the first and second joint portions forms a fused unitaryportion of the first and second thermoplastic components.

In the alternative or additionally thereto, in the foregoing embodiment,the unitary portion is a homogenous portion.

In the alternative or additionally thereto, in the foregoing embodiment,the first and second mating surfaces have a load bearing jointconfiguration such as a scarf joint, a step joint or any other suitablejoint for the particular application.

In the alternative or additionally thereto, in the foregoing embodiment,the step of fusion-joining the first and second substrates includesapplying a heat and a pressure to the first and second joint portionssimultaneously.

In the alternative or additionally thereto, in the foregoing embodiment,the method further includes consolidating the first and second jointportions with a press system.

In the alternative or additionally thereto, in the foregoing embodiment,the press system forms a first interface with a first surface of atleast one of the first and second joint portions and a second interfacewith a second surface of at least one of the first and second jointportions opposite the first and second joint portions from the firstinterface and the first and second surfaces are different than the firstand second mating surfaces.

In the alternative or additionally thereto, in the foregoing embodiment,all of the second thermoplastic component is the second joint portion.

In the alternative or additionally thereto, in the foregoing embodiment,the heat applied to the first and second joint portions is in the rangeof 600 to 800° F.

In the alternative or additionally thereto, in the foregoing embodiment,the first and second joint portions include a volume of the respectivefirst and second thermoplastic composite components.

In the alternative or additionally thereto, in the foregoing embodiment,a thickness of the first and second joint portions disposed between thefirst and second interfaces is greater or equal to 0.020 inches.

In the alternative or additionally thereto, in the foregoing embodiment,a first material of the first component and a second material of thesecond component each include at least one ply having a plurality ofreinforcing fibers.

In the alternative or additionally thereto, in the foregoing embodiment,the plurality of reinforcing fibers in the at least one ply has aunidirectional fiber orientation.

According to another embodiment of the present disclosure, a method forjoining thermoplastic components is provided. A first thermoplasticcomponent and a second thermoplastic component including a first jointportion and a second joint portion, respectively, are provided. Thefirst and second joint portions include a volume of the respective firstand second thermoplastic components. At least a portion of a surfacearea of each of the first and second joint portions includes arespective first and second mating surface. The first and second matingsurfaces of the respective first and second joint portions arepositioned in contact with one another. The first and second jointportions are consolidated with a press system. The first and secondjoint portions are fusion-joined thereby forming a single component.Fusion-joining the first and second joint portions forms a unitaryportion of the first and second thermoplastic components which is ahomogenous portion

In the alternative or additionally thereto, in the foregoing embodiment,the first and second mating surfaces have a load bearing jointconfiguration.

In the alternative or additionally thereto, in the foregoing embodiment,the press system forms a first interface with a first surface of atleast one of the first and second joint portions and a second interfacewith a second surface of at least one of the first and second jointportions opposite the first and second joint portions from the firstinterface and the first and second surfaces are different than the firstand second mating surfaces.

In the alternative or additionally thereto, in the foregoing embodiment,a first material of the first component and a second material of thesecond component each include at least one ply having a plurality ofreinforcing fibers.

In the alternative or additionally thereto, in the foregoing embodiment,the plurality of reinforcing fibers in the at least one ply has aunidirectional fiber orientation.

In the alternative or additionally thereto, in the foregoing embodiment,the step of fusion-forming the first and second joint portions includesapplying a heat and a pressure to the first and second joint portionssimultaneously and the heat applied to the first and second jointportions is in the range of 600° F. to 800° F.

According to another embodiment of the present disclosure, a method forrepairing a thermoplastic component is provided. A first mating surfaceof the thermoplastic component is positioned against a second matingsurface of a thermoplastic patch. The thermoplastic component has afirst side and an opposing second side. The first mating surface of thethermoplastic component is disposed on the first side. The thermoplasticpatch and the thermoplastic component are consolidated with a presssystem. The press system forms a first interface with at least one ofthe thermoplastic patch and the first side of the thermoplasticcomponent and a second interface with the second side of thethermoplastic component. The thermoplastic patch and the thermoplasticcomponent are fusion-joined. Fusion-joining the thermoplastic patch andthe thermoplastic component forms a fused unitary portion of thethermoplastic patch and the thermoplastic component which is ahomogenous portion.

In the alternative or additionally thereto, in the foregoing embodiment,the method further includes forming a load bearing configuration on thefirst mating surface.

The present disclosure, and all its aspects, embodiments and advantagesassociated therewith will become more readily apparent in view of thedetailed description provided below, including the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of components at a stage of ajoining process.

FIG. 1A illustrates a side cross-sectional view of the components ofFIG. 1 at a stage of a joining process.

FIG. 1B illustrates a side cross-sectional view of the components ofFIG. 1 at a stage of a joining process.

FIG. 1C illustrates a side cross-sectional view of an exemplary jointbetween the components of FIG. 1 .

FIG. 1D illustrates a side cross-sectional view of an exemplary jointbetween the components of FIG. 1 .

FIG. 2 illustrates a perspective view of components at a stage of ajoining operation.

FIG. 3 illustrates a perspective view of components at a stage of ajoining operation.

FIG. 3A illustrates a side cross-sectional view of the components ofFIG. 3 at a stage of a joining operation.

FIG. 4 illustrates a perspective view of components at a stage of ajoining operation.

FIG. 5 illustrates a perspective view of components at a stage of ajoining operation.

FIG. 5A illustrates another view of the components of FIG. 5 .

FIG. 5B illustrates a side cross-sectional view of the components ofFIG. 5 at a stage of the repairing process.

FIG. 5C illustrates a side-cross-sectional view of the components ofFIG. 5 at a stage of the repairing process.

FIG. 6 illustrates a flowchart for a method of joining components.

FIG. 7 illustrates a flowchart for a method of repairing a component.

DETAILED DESCRIPTION

It is noted that various connections are set forth between elements inthe following description and in the drawings. It is noted that thesejoints are general and, unless specified otherwise, may be direct orindirect and that this specification is not intended to be limiting inthis respect. A coupling between two or more entities may refer to adirect connection or an indirect connection. An indirect connection mayincorporate one or more intervening entities. It is further noted thatvarious method or process steps for embodiments of the presentdisclosure are described in the following description and drawings. Thedescription may present the method and/or process steps as a particularsequence. However, to the extent that the method or process does notrely on the particular order of steps set forth herein, the method orprocess should not be limited to the particular sequence of stepsdescribed. As one of ordinary skill in the art would appreciate, othersequences of steps may be possible. Therefore, the particular order ofthe steps set forth in the description should not be construed as alimitation.

Referring to FIGS. 1, 1A-D, and 6, aspects of the present disclosureinclude an exemplary method 600 for joining two or more components, suchas a first component 200 and a second component 202. Accordingly, themethod 600 may provide for forming a unitary component 214 from thefirst and second components 200, 202 such that the unitary component 214is a homogenous consolidated component identical to the parentsubstrates (i.e., the first and second components 200, 202). As shown inFIG. 1 , the first and second components 200, 202 may be composite skinpanels as may be used, for example, to form an exterior surface of anaircraft. However, the present disclosure should not be understood to belimited to joining or repairing aircraft components.

One or both of the first and second components 200, 202 may be made allor in part from a composite material, for example, a thermoplasticmaterial. One or both of the first and second components 200, 202 mayconsist of one or more plies (i.e., layers) of composite material whichhave been stacked and joined to form the respective component 200, 202.In some embodiments, one or more of the plies may include a plurality ofreinforcing fibers embedded therein. The plurality of fibers disposedwithin the composite plies may be continuous or discontinuous. Thefibers may be parallel or substantially parallel to one another. As usedherein, the fibers are substantially parallel if they extend along acommon direction +/−10 degrees. The fibers may also have amulti-directional configuration, e.g., a woven fiber orientation. Insome embodiments, one or both of the first and second components 200,202 may include one or more plies having unidirectional fibers and oneor more other plies having multidirectional fibers.

With reference to step 602 of the method 600, the first component 200includes a first joint portion 204 including at least a portion of thevolume of the first component 200 (i.e., a three-dimensional portion ofthe first component 200). A first mating surface 208 forms at least aportion of the surface area of the first joint portion 204. Similarly,the second component 202 includes a second joint portion 206 includingat least a portion of the volume of the first component 200 (i.e., athree-dimensional portion of the second component 202). A second matingsurface 210 forms at least a portion of the surface area of the secondjoint portion 206. The first and second joint portions 204, 206, asshown in the figures, are provided to better convey the aspects of thepresent disclosure, however, it should be understood that jointportions, such as the first and second joint portions 204, 206, may havea different size, shape, or orientation than what is illustrated in thefigures provided.

As best shown in FIG. 1A, the first mating surface 208 of the firstjoint portion 204 is positioned in contact with the second matingsurface 210 of the second joint portion 206 (step 604). The first andsecond components 200, 202 are positioned with respect to one anothersuch that following the joining process the resultant unitary component214 (see, e.g., FIG. 1B) will have the desired orientation. Auxiliaryfixturing (not shown), for example, mechanical support structures, maybe required to provide additional support to distal portions of one orboth of the first and second components 200, 202 with respect to thefirst and second joint portions 204, 206 in order to provide sufficientstability and prevent undesirable movement between the first and secondjoint portions 204, 206 during the joining process.

The first and second mating surfaces 208, 210 may have a load bearingjoint configuration to improve the structural integrity of the unitarycomponent 214. For example, the first and second mating surfaces 208,210 may have corresponding load bearing joint configurations which mayinclude, for example, a scarf configuration (see FIGS. 1A-C), a stepconfiguration (see FIG. 1D), or any other suitable load bearing jointconfiguration to meet the specific structural requirements of theunitary component 214.

Once the first and second mating surfaces 208, 210 are positioned incontact with one another, the first and second joint portions 204, 206of the first and second components 200, 202 are consolidated with apress system 100 configured to apply heat and a pressure to the firstand second joint portions 204, 206 (step 606), or any other suitablesystem for applying a heat and a pressure to the first and second jointportions 204, 206. The press system 100 may include press platens and/orone or more tooling portions, such as first and second tooling portions102, 104, tailored specifically to the mating surface 208, 210 geometryof the first and second joint portions 204, 206 (e.g., the first andsecond tooling portions 102, 104 may be configured to conform to thesurface geometry of the first and second mating surfaces 208, 210,respectively) (Step 603).

Consolidating the first and second joint portions 204, 206 includespositioning the first and second tooling portions 102, 104 in contactwith the first and second components 200, 202 so as to form an interfacewith the first and second components 200, 202. For example, as shown inFIGS. 1A and 1B, the first tooling portion 102 may form a firstinterface 106 with the first and second components 200, 202 proximatethe first and second joint portions 204, 206. The second tooling portion104 may form a second interface 108 with the first and second components200, 202 proximate the first and second joint portions 204, 206 oppositethe first interface 106 with respect to the first and second components200, 202. When consolidating the first and second joint portions 204,206, the press system 100 may apply a pressure to one or both of thefirst and second components 200, 202 via the first and second toolingportions 102, 104.

The first and second interfaces 106, 108 may be formed between the firstand second tooling portions 102, 104 and a surface of one or both of thefirst and second joint portions 204, 206 different than the respectivefirst and second mating surfaces 208, 210. As shown in FIG. 1 , thepress system 100 may apply pressure to the first and second jointportions 204, 206 in a general direction of forces F₁, F₂ (i.e., thepress system 100 applies force F₁ at the first interface 106 and forceF₂ at the second interface 108). The press system 100 may be ahydraulic, pneumatic, or electromechanical assembly or any othersuitable assembly for providing adequate pressure to the above-describedcomponents, such as the first and second components 200, 202.

As discussed above, in some embodiments, one or both of the first andsecond tooling portions 102, 104 may be tailored to the specificgeometry of the first and second components 200, 202 at the respectivefirst and second interfaces 106, 108. As shown in FIG. 1A, a length L ofone or both of the first and second interfaces 106, 108 maysubstantially correspond to a combined length of the first and secondjoint portions 204, 206. However, the length L of one or both of thefirst and second interfaces 106, 108 may be longer or shorter than thecorresponding length of the first and second joint portions 204, 206,individually or in combination.

As shown in FIG. 1A, the first and second joint portions 204, 206 have athickness T disposed between the first and second interfaces 106, 108.In some embodiments, the thickness T of the first and second jointportions 204, 206 may be substantially the same. However, in otherembodiments, the thickness T of one of the first and second jointportions 204, 206 may be greater or less than the thickness T of theother of the first and second joint portions 204, 206. In someembodiments, the thickness T may be in the range of 0.020 to 1.500inches. In some other embodiments, the thickness T may exceed 1.5inches.

The first and second joint portions 204, 206 of the respective first andsecond components 200, 202 are fusion-joined by applying a heat and apressure to the first and second joint portions 204, 206 for asufficient amount of time to form a fused unitary portion 212 (step 608,see FIG. 1B). For example, the volume of the first and second jointportions 204, 206 may be melted while applying heat and pressure withthe press system 100. In some embodiments, the heat applied to the firstand second joint portions 204, 206 by the press system 100 may be in therange of 700 to 800° F. Additionally, in some embodiments, the pressureapplied by the press system 100 to the first and second tooling portions102, 104 may be up to 1000 psi. In some other embodiments, the pressureapplied by the press system 100 to the first and second tooling portions102, 104 may be up to 2500 psi. In still some other embodiments, thepressure applied by the press system 100 to the first and second toolingportions 102, 104 may be greater than 2500 psi. The pressure required tobe applied to the tooling portions 102, 104 may depend on a number offactors, for example, the size and complexity of the tooling portiongeometry. It should be understood that the resulting pressure applied tothe first and second joint portions 204, 206 may be different than thepressure applied to the first and second tooling portions 102, 104.

Fusion-joining of the first and second joint portions 204, 206 forms theunitary portion 212 which is a homogenous portion with respect to thematerial of the first and second components 200, 202 (i.e., noadditional material is introduced, e.g., adhesives, welding strips,composite fillers, films, or coatings, etc.). The unitary joint portion212 may have a fiber orientation which is substantially similar to thefiber orientation of one or both of the first and second components 200,202. Accordingly, through the fusion-joining process, the first andsecond joint portions 204, 206 are formed into the unitary portion 212thereby forming the unitary component 214 from the first and secondcomponents 200, 202. Subsequent to fusion-joining the first and secondjoint portions 204, 206, the unitary portion 212 may be cooled to allowthe unitary portion 212 to solidify and/or demold (Step 610).

Referring now to FIGS. 2-4 , aspects of the present disclosure areillustrated with components which are different than the first andsecond components 200, 202 illustrated in FIG. 1 . As previouslydiscussed, the method 600 for joining components may be applied to anysuitable components. For example, FIG. 2 shows the first and secondcomponents 200, 202 which are exemplary stiffeners disposed between thefirst and second tooling portions 102, 104 of the press system 100during a stage of the method 600. FIG. 3 shows the first and secondcomponents 200, 202 during a stage of the method 600 wherein the firstcomponent 200 is a skin panel, similar to the skin panels of FIG. 1(before or after the discussed joining process), and the secondcomponent 202 is a plurality of stiffeners, similar to the stiffeners ofFIG. 2 (before or after the discussed joining process). Finally, FIG. 4shows the first and second components 200, 202 during a stage of themethod 600 wherein the first and second components 200, 202 areskin-stiffened assemblies, for example, the skin-stiffened assemblyshown in FIG. 3 at a stage of the method 600.

As previously discussed, the first and second joint portions 204, 206have a thickness T disposed between the first and second interfaces 106,108. As shown in FIG. 3A, the thickness T between the first and secondinterfaces 106, 108 of the respective first and second tooling portionsmay be a combined thickness of the first and second joint portions 204,206.

Referring to FIGS. 5, 5A-C, and 7, aspects of the present disclosureinclude an exemplary method 700 for repairing a component, for example,the first component 200. Accordingly, aspects of the present disclosuremay be used to repair damage or a defect, such as damage/defect 216,present in the first component 200. A defect can be cosmetic, such as acrack, groove, or pit and may result from process deviations duringmanufacturing such as voids, porosity, polymer rich or starved areas,etc. Damage can be structural, such as a small crack or a large crackwhich spans two surfaces of the first component 200, porosity, adelamination resulting from an impact or a tool drop, etc. A structuraldefect may be a defect which facilitates crack propagation or otherfailure mechanisms. A cosmetic defect may detract from aesthetics of theexposed surfaces of the first component 200. In some embodiments,repairing the first component 200 may require a second component 202configured as, for example, a patch formed from previously joined pliesof thermoplastic material (see, e.g., FIGS. 5 and 5A-B). In otherembodiments, the second component (i.e., the patch) may be formed as aply-by-ply layup tailored to the damage/defect 216 and the first matingsurface 208 of the first joint portion 204 (see, e.g., FIG. 5C). Forexample, individual plies may be cut to the desired contour and laid upin the scarfed area as shown in FIG. 5C. However, repairing the firstcomponent 200 according to aspects of the present disclosure may beperformed, in some circumstances (e.g., repairing a crack) withoutrequiring the additional material of the second component 202.

Optionally, one or both of the first and second mating surfaces 208, 210of the respective first and second components 200, 202, may be preparedfor fusion-joining by processing the mating surface 208, 210 to removedamaged material (e.g., by sanding, cutting, etc.), apply a load bearingconfiguration such as the scarf configuration (see, e.g., FIG. 5A),apply a surface texture configuration, or other suitable configurationto the mating surface 208, 210 (step 702). For example, the matingsurface 208, 210 processing may be performed proximate or surroundingthe defect 216 on a surface of the first component 200.

The first mating surface 208 of the first joint portion 204 ispositioned in contact with the second mating surface 210 of the secondjoint portion 206 (step 704). As shown in FIG. 5A, in some embodiments,the second joint portion 206 may include all or substantially all of thevolume of the second component 202. The first and second components 200,202 are positioned with respect to one another such that following therepairing process the unitary component 214 will have the desiredorientation.

Once the first and second mating surfaces 208, 210 are positioned incontact with one another, the first and second joint portions 204, 206of the first and second components 200, 202 are consolidated with apress system 100 (step 706). As described above, the press system 100may include one or more tooling portions, such as first and secondtooling portions 102, 104, configured to form an interface with thefirst and second components 200, 202. For example, as shown in FIGS. 5Band 5C, the first tooling portion 102 may form a first interface 106with the first and second components 200, 202 proximate the first andsecond joint portions 204, 206. The second tooling portion 104 may forma second interface 108 with the first and second components 200, 202proximate the first and second joint portions 204, 206 opposite thefirst interface 106 with respect to the first and second components 200,202. The first and second interfaces 106, 108 may be formed between thefirst and second tooling portions 102, 104 and a surface of one or bothof the first and second joint portions 204, 206 different than therespective first and second mating surfaces 208 210. Similar to Step603, first and second tooling portions 102, 104 tailored specifically tothe mating surface 208, 210 geometry of the first and second jointportions 204, 206 may be provided (Step 703).

The first and second joint portions 204, 206 of the respective first andsecond components 200, 202 are fusion-joined by applying a heat and apressure to the first and second joint portions 204, 206 for asufficient amount of time to form a unitary portion 212 (step 708, seeFIG. 1B). Fusion-joining of the first and second joint portions 204, 206forms the unitary portion 212 which is a homogenous portion with respectto the first and second components 200, 202. Thus, the unitary portion212 may have a material structure which is substantially identical tothe material structure of one or both of the first and second components200, 202. Accordingly, through the fusion-joining process, the first andsecond joint portions 204, 206 are formed into the unitary portion 212thereby forming the unitary component 214 from the first and secondcomponents 200, 202. Subsequent to fusion-joining the first and secondjoint portions 204, 206, the unitary portion 212 may be cooled to allowthe unitary portion 212 to solidify and/or demold (Step 710).

While the methods above are described with respect to the first andsecond components 200, 202, the present disclosure is not limited tojoining or repairing only two components. Accordingly, 3 or morecomponents may be joined at a common joint. A press system, such as thepress system 100, may also form more than two interfaces with thecomponents to be joined or repaired.

While various aspects of the present disclosure have been presented, itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible within the scope of thepresent disclosure. For example, the present disclosure as describedherein includes several aspects and embodiments that include particularfeatures. Although these particular features may be describedindividually, it is within the scope of the present disclosure that someor all of these features may be combined with any one of the aspects andremain within the scope of the present disclosure. Accordingly, thepresent disclosure is not to be restricted except in light of theattached claims and their equivalents.

What is claimed is:
 1. A method for joining fiber-reinforcedthermoplastic composite components, the method comprising: providing afirst fiber-reinforced thermoplastic composite component and a secondfiber-reinforced thermoplastic composite component comprising a firstjoint portion and a second joint portion, respectively, at least aportion of a surface area of each of the first and second joint portionscomprising a respective first and second mating surface; positioning thefirst and second mating surfaces of the respective first and secondjoint portions in contact with one another; consolidating the first andsecond joint portions with a press system; and joining the first andsecond joint portions by applying heat and pressure to the first andsecond joint portions with the press system, wherein the press systemforms a first interface with a first surface of at least one of thefirst and second joint portions and a second interface with a secondsurface of at least one of the first and second joint portions oppositethe first and second joint portions from the first interface and whereinthe first and second surfaces are different than the first and secondmating surfaces, and wherein joining the first and second joint portionscomprises melting an entire volume of the first and second jointportions to form a fused unitary portion of the first and secondfiber-reinforced thermoplastic composite components.
 2. The method ofclaim 1, wherein the unitary portion is a homogenous portion.
 3. Themethod of claim 1, wherein the first and second mating surfaces have aload bearing joint configuration.
 4. The method of claim 3, wherein theload bearing joint configuration is a step configuration.
 5. The methodof claim 3, wherein the load bearing joint configuration is a scarfconfiguration.
 6. The method of claim 1, wherein the step of joining thefirst and second joint portions includes applying a heat and a pressureto the first and second joint portions simultaneously.
 7. The method ofclaim 6, wherein the heat applied to the first and second joint portionsis in a range of 600 to 800 T.
 8. The method of claim 1, wherein athickness of the first and second joint portions disposed between thefirst and second interfaces is greater than 1.5 inches.
 9. The method ofclaim 1, wherein a first material of the first component and a secondmaterial of the second component each include at least one ply having aplurality of reinforcing fibers.
 10. The method of claim 9, wherein theplurality of reinforcing fibers of the at least one ply in each of thefirst material and the second material have a unidirectional fiberorientation.
 11. The method of claim 1, wherein the first mating surfaceand the second mating surface each extend from the first surface to thesecond surface.
 12. The method of claim 1, wherein the first componentis a skin panel and the second component is a stiffener.
 13. The methodof claim 1, wherein the press system includes a first tooling portionand a second tooling portion, the first tooling portion forming thefirst interface with the first surface and the second tooling portionforming the second interface with the second surface and wherein the oneor both of the first interface and the second interface are non-planar,the method further comprising: tailoring one or both of the firsttooling portion and the second tooling portion to a specific geometry ofthe first component and the second component at the respective firstinterface and second interface.
 14. A method for joiningfiber-reinforced thermoplastic composite components, the methodcomprising: providing a first fiber-reinforced thermoplastic compositecomponent and a second fiber-reinforced thermoplastic compositecomponent comprising a first joint portion and a second joint portion,respectively, the first and second joint portions comprising a volume ofthe respective first and second thermoplastic components and at least aportion of a surface area of each of the first and second joint portionscomprising a respective first and second mating surface; positioning thefirst and second mating surfaces of the respective first and secondjoint portions in contact with one another; consolidating the first andsecond joint portions with a press system; and joining the first andsecond joint portions, wherein joining the first and second jointportions comprises melting an entire volume of the first and secondjoint portions to form a fused unitary portion of the first and secondfiber-reinforced thermoplastic composite components which is ahomogenous portion.
 15. The method of claim 14, wherein the first andsecond mating surfaces have a load bearing joint configuration.
 16. Themethod of claim 15, wherein the load bearing joint configuration is astep configuration.
 17. The method of claim 15, wherein the load bearingjoint configuration is a scarf configuration.
 18. The method of claim14, wherein a first material of the first fiber-reinforced thermoplasticcomposite component and a second material of the second fiber-reinforcedthermoplastic composite component each include at least one ply having aplurality of reinforcing fibers.
 19. The method of claim 14, wherein thestep of joining the first and second joint portions includes applyingheat and pressure to the first and second joint portions with the presssystem, and wherein the heat applied to the first and second jointportions is in a range of 600 to 800° F.
 20. The method of claim 14,wherein the press system forms a first interface with a first surface ofat least one of the first and second joint portions and a secondinterface with a second surface of at least one of the first and secondjoint portions opposite the first and second joint portions from thefirst interface and wherein the first and second surfaces are differentthan the first and second mating surfaces; and wherein the press systemincludes a first tooling portion and a second tooling portion, the firsttooling portion forming the first interface with the first surface andthe second tooling portion forming the second interface with the secondsurface and wherein the one or both of the first interface and thesecond interface are non-planar, the method further comprising:tailoring one or both of the first tooling portion and the secondtooling portion to a specific geometry of the first component and thesecond component at the respective first interface and second interface.